Production
Currently, the PRADO steel panel radiator plant is an industry leader, being the largest manufacturer and supplier of steel panel radiators in Russia and the CIS. The company's advanced technological equipment and extensive experience in welding production make it possible to create high-quality mass-market products with excellent strength characteristics and modern design.
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Production of PRADO Radiators
The entire production process for PRADO radiators can be divided into four main stages: stamping, welding, painting, and assembly & packaging.
Stage 1. Cold Stamping
PRADO radiators are made from high-quality low-carbon structural steel with a thickness of at least 1.2 mm.
Cold sheet stamping is used to manufacture our heating appliances.
The principle is that, using a die installed in a press, the supplied sheet material is formed, cut, and bent with a force ranging from 16 to 600 tonnes.
This process produces the components of the future radiator.
Stage 2. Welding
Radiators are welded on a modern, fully automatic LEAS welding line. This Italian-made LEAS line was the first of its kind to be installed in Russia, here at our factory.
In the production of PRADO steel panel radiators, three types of contact welding are used: seam, spot, and projection welding. Seam welding joins the radiator panels along their perimeter. Spot welding connects the half-panels together and attaches the convector sheet to the panel. Projection welding is used to weld the connectors and fittings.
Before welding the half-panels, an insert is placed between them for the subsequent welding of the connectors and fittings. Next, the half-panels are stacked using a rotating turntable and fed to the welding line. The aligned half-panels are then welded on a multi-point machine. This step determines the radiator’s burst pressure rating. A convector sheet is then welded on the next multi-point machine, which directly affects the radiator’s heat output.
After the half-panels and convector sheet are welded, the radiator panel is perimeter-welded using longitudinal and transverse seam welding machines. To monitor process parameters, the welded panels undergo selective pressure tests, which allow operators to maintain consistently high welding quality.
One of the most complex operations on the welding line is welding the connectors and fittings. During this process, depending on the selected programme, one, two, or three panels are automatically stacked, the connectors and fittings are precisely positioned between them, and the radiator is welded. After that, brackets and supports are welded to the radiator.
All welding line operations are controlled by a SIEMENS-based control system, which significantly reduces the risk of human error and ensures consistently high product quality.
After welding, 100% of radiators are tested for leaks at a pressure 1.5 times higher than the maximum operating pressure.
Stage 3. Painting
After welding, the radiators are placed on a conveyor for painting. Painting is one of the most important steps in radiator production.
PRADO radiators receive three protective layers: a phosphate layer to treat the metal surface, an immersion primer, and a powder coating.The most important stage is multi-stage surface preparation, carried out using a seven-zone process that ensures excellent adhesion for subsequent coatings. The phosphate coating formed during surface preparation provides strong corrosion protection for the painted metal surfaces.
Next, each radiator undergoes high-quality priming using a primer supplied by one of Europe’s leading manufacturers.
After careful powder spraying, the radiators pass through a polymerisation oven.
Stage 4. Assembly and Packaging
After painting, the top and side panels are fitted, brackets and a set of spare parts are added, and plugs and a thermostatic insert are installed. Each radiator is then inspected, and if it meets all requirements, a certificate with an inspection mark is included. Finally, plastic protective corners are fitted and the radiator is packaged in shrink film.
